ABB ACS560 Installation manual

—
ABB GENERAL PURPOSE DRIVES
ACS560 standard control program
Quick installation and start-up guide
ENEnglish . . . . . . . 3
HI
 ........ 171
3AXD50000042620 Rev J MUL
EFFECTIVE: 2022-08-16

EN - Quick installation and
start-up guide
This guide instructs how to install and start-up the ACS560 drive of all frame sizes
(R0...R8). For complete information, see the drive ACS560 standard control program
firmware manual (3AXD50000044997[English]) and ACS560 drives (0.75 to 160
kW, 1.0 to 215 hp) hardware manual (3AXD50000044998[English]).
General considerations
￭Obey the safety instructions
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
•If you are not a qualified electrician, do not do electrical installation work.
• Do not work on the drive, motor cable or motor when main power is
applied. If the drive is already connected to the input power, wait for 5
minutes after disconnecting the input power.
• Do not work on the control cables when power is applied to the drive or
to the external control circuits.
• Use the lifting eyes of the drive when you lift the drive. Do not tilt the
drive. The drive is heavy and its center of gravity is high. An overturning
drive can cause physical injury.
• Make sure that debris from borings and grindings does not enter the
drive when installing.
• Make sure that the floor below the drive and the wall where the drive is
installed are non-flammable.
￭Reform the capacitors
Reform the capacitors if the drive is stored for a year or more.
The manufacturing date is on the type designation label which is attached to the
drive. The serial number format MYYWWRXXXX represents the month, year and
the week.
YY: 13, 14, 15, … for 2013, 2014, 2015, …
WW: 01, 02, 03, … for week 1, week 2, week 3, …
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For information on reforming the capacitors, see Converter module capacitor
reforming instructions (3BFE64059629 [English]).
￭Select the power cables
Size the power cables according to local regulations to carry the nominal current
given on the type designation label of your drive. See Ratings (page 127).
￭Ensure the cooling
The maximum ambient temperature without derating is:
• 50 °C (+122 °F) for R0...R2 frames
• 40 °C (+104 °F) for R3...R8 frames
No condensation or frost is allowed. For more information on the ambient
temperature, see the hardware manual.
￭Protect the drive and input power cable
If you use gG fuses, make sure that the operating time of the fuse is below 0.5
seconds. Follow the local regulations.
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Install the drive
You can install the drive
• to a DIN installation rail with integrated lock. This method applies to frames
R0...R2 only.
or
• with screws to a suitable surface (wall or assembly plate). This method applies
to all frames R0...R8.
￭Required tools for installing the drive
• A drill and suitable drill bits.
• Screwdriver (Flat head, Phillips head, and Torx)
• wrench with suitable bits and sizes (appropriate for the installation hardware
used). See the required screw sizes in below installation instructions
• A tape measure and spirit level.
• Personal protective equipment.
￭Installing a drive to DIN installation rail (frames R0...R2 only)
1. On the top center of the drive move the locking part to the left.
2. Push and hold the locking button down.
3. Put the top tabs on the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN installation rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure the drive is installed correctly.
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￭Removing drive from the DIN installation rail (frames R0...R2 only)
To remove the drive, open the locking part using a flat-head screwdriver.
￭Installing a drive with screws (frames R0...R8)
All drives of frames R0...R8 can be installed on a wall with screws. See the required
screw sizes in below mounting dimensions table. See also Dimensions, weights
and free space requirements (page 132)
WARNING!
The drive module (frames R6...R8) is heavy (45 to 70 kg). Consider the
following:
• Use a suitable lifting device.
• Do not lift the module manually.
• Make sure that the wall and the fixing devices can carry the weight. See
data in the table below.
1. Mark the mounting hole locations using the mounting template included in
the package.
Mounting dimensionsMounting template
R8R7R6R5R4R3R2R1R0Frames
M8M6M5Screws
(mm)
1
658583531581619473191a
701623571612-b
2632452131601487550
-75d
20075e
70.055.045.028.023.014.867.544.574.47Weight
(kg)
2. Drill the mounting holes.
3. Tighten the screws into the mounting holes.
4. Position the drive onto the screws on the wall.
5. Tighten the mounting screws.
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234
5
See the example of mounting screws in frame R0
6. Frames R5...R8 only: Remove the front cover with fastening screws (6a), move
the cover to the top side (6b) and then up (6c).
7. Frames R5...R8 only: Attach the cable conduit box to the drive frame.
Note: Cable conduit box is optional and is not part of standard delivery.
8. Frames R5...R8 only: Tighten the box screws: two at the top and four at the
bottom.
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6a
6b
6a
6c
7
8
8
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Measuring the insulation resistance of the motor and motor
cable
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or
maintenance work.
1. Follow the electrical safety precautions. See Electrical safety instructions in
the hardware manual.
2. Make sure that the motor cable is disconnected from the drive output terminals.
3. Measure the insulation resistance between each phase conductor and the
protective earth conductor. Use a measuring voltage of 1000 V DC. The
insulation resistance of an ABB motor must be more than 100 Mohm (reference
value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to
the manufacturer’s instructions.
Note: Moisture inside the motor reduces the insulation resistance. If you think
that there is moisture in the motor, dry the motor and do the measurement
again.
1000 V DC,
>100 Mohm
U1-PE, V1-PE, W1-PE
ohm
M
3~
U1
V1
W1 PE
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Connecting the power cables
￭Connection diagram
For alternatives, see hardware manual.1
Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b)
if the conductivity of the shield does not meet the requirements for the PE conductor
(see hardware manual).
2
360° grounding is recommended if shielded cable is used. Ground the other end of the
input cable shield or PE conductor at the distribution board.
3
360° grounding is required.4
External brake resistor (for frames R4...R8 only).5
Use a separate grounding cable if the shield does not meet the requirements of IEC
61439-1 and there is no symmetrically constructed grounding conductor in the cable.
For more information, see hardware manual.
6
Note: If there is a symmetrically constructed grounding conductor on the motor cable in
addition to the conductive shield, connect the grounding conductor to the grounding ter-
minal at the drive and motor ends.
Do not use an asymmetrically constructed motor cable for motors above 30 kW. Earthing
at the motor increases bearing current and power consumption, damages the motor
bearing and even the motor.
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￭Connection procedure: frames R0…R2
If the drive is connected on an IT (ungrounded) system, make sure that the
EMC filter and Varistor (VAR) is disconnected. For more information, see
hardware manual.
1. Remove the front cover as follows:
• Loosen the retaining screw with a screwdriver (1a).
• Lift the cover from the bottom outwards (1b).
1a
1b
Motor cable
2. Prepare the ends of the cable as illustrated in the figure. Two different motor
cable types are shown in the figures (2a.and 2b).
Note: The bare shield will be grounded 360°.
PE
2a
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PE
2b
3. Connect the motor cable as follows:
• Ground the shield 360° by tightening the clamp of the power cable grounding
shelf onto the stripped part of the cable (3a).
• Connect the twisted shield of the cable to the grounding terminal (3b).
• Connect the phase conductors of the cable to the terminals of T1/U, T2/V and
T3/W.
3a
3b
3c
• Tighten the screws to the torque given below.
R2R0…R1Frame size
lbf·ftN·mlbf·ftN·m
0.9…1.11.2…1.50.40.5…0.6T1/U. T2/V. T3/W
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Input power cable
4. Prepare the ends of the cable as illustrated in the figure.
Note: The bare shield will be grounded 360°. Mark the pigtail made from the shield
as a PE conductor with yellow-and-green color
PE
PE
5. Connect the input power cable as follows:
• Connect the twisted shield of the cable to the grounding terminal (5a).
• Connect the phase conductors of the cable to the L1, L2 and L3 terminals.
5a
5b
• Tighten the screws to the torque given below:
R2R0…R1Frame size
lbf·ftN·mlbf·ftN·m
0.9…1.11.2…1.50.40.5…0.6L1, L2, L3
6. Connect the braking resistor cable as the motor cable. See step 3.
7. Ground the shield 360° (6a).
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8. Connect the twisted shield to the grounding terminal (6b) and the conductors
to the UDC+/R+ and R- terminals (6c).
6a
6b
6c
9. Tighten the screws to the torque given below.
R2R0…R1Frame size
lbf·ftN·mlbf·ftN·m
0.9…1.11.2…1.50.40.5…0.6UDC+/R+, R-
Finalization
10. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360° at the lead-through of the motor
terminal box.
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￭Connection procedure, frames R3...R4
If the drive is connected on an IT (ungrounded) system, make sure you have
disconnected the EMC filter and Varistor (VAR). See EMC filter (page 30).
1. Remove the front cover as follows:
• Loosen the retaining screw with a screwdriver (1a).
• Push the front cover upward to uncouple top buckle (1b), and lift the cover
from the bottom outwards (1c).
1c
2a
1b
Motor cable
2. Prepare the ends of the cable as illustrated in the figure. Two different motor
cable types are shown in the figures 2a and 2b.
Note: The bare shield will be grounded 360°.
PE
2a
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PE
2b
3. Connect the motor cable as follows:
If the power cable is temporarily removed from the grounding shelf, connect the
motor and input power cables except the 360° grounding, and then reinstall the
grounding shelf.
• Ground the shield 360° by tightening the clamp of the power cable grounding
shelf onto the stripped part of the cable (4a).
• Connect the twisted shield of the cable to the grounding terminal (4b).
• Connect the phase conductors of the cable to the T1/U, T2/V and T3/W
terminals.
• Tighten the screws to the torque given below:
R4R3Frame size
lbf·ftN·mlbf·ftN·m
3.04.01.8…3.32.5…4.5T1/U. T2/V. T3/W.
4a
4b
4c
Notes:
• The screws are of different length. Install them at correct locations.
• After reinstalling the grounding shelf, you can make the 360° grounding for
the cables.
Input power cable
4. Prepare the ends of the cable as illustrated in the figure.
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Note: The bare shield is grounded 360°. Mark the pigtail made from the shield as
a PE conductor with yellow-and-green color.
PE
PE
5. Connect the input power cable as follows:
• Ground the shield 360° by tightening the clamp of the power cable grounding
shelf onto the stripped part of the cable (6a).
• Connect the twisted shield of the cable to the grounding terminal (6b).
• Connect the phase conductors of the cable to the terminals of L1, L2 and L3.
• Tighten the screws to the torque given below.
R4R3Frame size
lbf·ftN·mlbf·ftN·m
3.04.01.8…3.32.5…4.5L1, L2, L3
6a
6b
6c
6. Connect cable by the motor cable method mentioned in step 3.
7. Ground the shield 360° (7a).
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8. Connect the twisted shield to the grounding terminal (7b).
9. For R3, connect the conductors to the R+ and R- terminals (7c).
10. Tighten to the torque given below.
R3Frame size
lbf.ftN.m
1.8...3.32.5...4.5R+, R-
7c
7b
7a
Finalization
11. Install the grounding shelf for the control cables (included with the mounting
screws in a plastic bag in the delivery) onto the grounding shelf for the power
cables.
Electrical installation 85
Finalization
11. Install the grounding shelf for the control cables (included with the mounting
screws in a plastic bag in the delivery) onto the grounding shelf for the power
cables.
12. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360 degrees at the lead-through of
the motor terminal box.
8
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12. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360° at the lead-through of the motor
terminal box.
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￭Connection procedure, frames R5…R8
If the drive will be connected on an IT (ungrounded) system, make sure you
have disconnected the EMC filter and Varistor (VAR). See EMC filter (page 30).
1. Attach the residual voltage warning sticker next to the control board.
2. Remove the side plates of the cable box as follows:
• Remove the retaining screws.
• Slide the walls out.
2
1
3. Remove the shroud on the power cable terminals by releasing the clips with a
screwdriver and pulling the shroud out.
4. Knock out holes in the shroud for the cables to be installed.
5. Frame R8 only: If you install parallel cables, also knock out holes in the lower
shroud for the cables to be installed.
Frame R8
4
86 Electrical installation
Connection procedure, frames R6…R8
WARNING! If the drive will be connected on an IT (ungrounded) system,
make sure you have disconnected the EMC filter and ground-to-phase varistor.
See page 71. If the drive will be connected on a corner-grounded TN system, make
sure you have disconnected the EMC filter. See page 71.
1. Attach the residual voltage warning sticker next to the control board.
2. Remove the side plates of the cable box as follows:
• Remove the retaining screws.
• Slide the walls out.
3. Remove the shroud on the power cable terminals by releasing the clips with a
screwdriver and pulling the shroud out.
4. Knock out holes in the shroud for the cables to be installed.
5. Frames R8: If you install parallel cables, also knock out holes in the lower shroud
for the cables to be installed.
1
2
34
5
R8…R8
3
86 Electrical installation
Connection procedure, frames R6…R8
WARNING! If the drive will be connected on an IT (ungrounded) system,
make sure you have disconnected the EMC filter and ground-to-phase varistor.
See page 71. If the drive will be connected on a corner-grounded TN system, make
sure you have disconnected the EMC filter. See page 71.
1. Attach the residual voltage warning sticker next to the control board.
2. Remove the side plates of the cable box as follows:
• Remove the retaining screws.
• Slide the walls out.
3. Remove the shroud on the power cable terminals by releasing the clips with a
screwdriver and pulling the shroud out.
4. Knock out holes in the shroud for the cables to be installed.
5. Frames R8: If you install parallel cables, also knock out holes in the lower shroud
for the cables to be installed.
1
2
34
5
R8…R8
3
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